54.

01

Wiring

Wiring Repair and Replacement

Repair and Replacement

IMPORTANT: Before repairing or replacing any damaged electrical system parts, find and correct the
cause of the damage; otherwise, it could occur again.
Wiring insulation can be damaged by internal or
external heat, chafing, kinking, breaking, cracking, or
saturation with oil or grease.
Discolored wire insulation (brown) is caused by longterm overheating of the wire itself. Melted insulation is
usually caused by an external heat source.
Repair or replace damaged wiring. Whether you repair
or replace the wiring depends on the type of damage.
See Table 1.
Wiring Damage
Type of Damage

Remedy

Broken wire

Repair or replace*

Kinked wire

Replace

Oil-soaked insulation

Replace

Cracked insulation
Melted insulation
Worn or missing insulation
Discolored insulation

Repair if minor, replace if not

Replace
Repair
Replace

* Repair the break by soldering the two broken ends together if there is
enough slack in the wire; otherwise solder in a new section of wire. See
"Repairing Broken Wire" for instructions.

Table 1, Wiring Damage

not possible, cover the sharp edge with protective

vinyl trim (18-02188-001) or use convoluted tubing
to protect the insulation.
3. Cover the repaired section of wiring with plastic
convoluted tubing.

Replacing Damaged Wire

CAUTION
Never replace a wire with a smaller gauge wire.
Wire gauge is selected by electrical load and
current capabilities. Overheating may occur if a
wrong gauge wire is used.
1. Replace damaged wire using a solder splice. See
"Repairing Broken Wire" for instructions. Use only
solder splices.
IMPORTANT: If the damaged wire is 12 gauge or
larger, do not replace a section of it, replace the entire
wire.
2. If the insulation has been discolored, find out what
is causing the wire to overheat and correct it.
3. If the insulation has been melted, check the routing
of the wiring and find the problem. Reroute the
wiring if possible and secure it with clamps. If
rerouting is not possible, use a heat shield to
protect the wire.

Repairing Electrical Connections

Repairing Damaged Wire Insulation

1. Find the cause of the damage or corrosion and

correct the problem.

1. Using heat shrink, cover the damaged area. Overlap the damaged area at least 3/4 inch (20 mm)
on both sides.

2. Using a solution of baking soda and water, clean

corroded connectors with a wire brush, then dry
the area. Replace any damaged connectors.

IMPORTANT: Do not repair the insulation if the wire

underneath is also damaged. Remove and replace the
damaged section.

3. Spray any exposed connectors, such as ground

terminals, with dielectric red enamel. See Table 2.

2. If the insulation is chafed, find the source of

chafing and route the wiring away from it. If this is

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54.01

Wiring

Wiring Repair and Replacement

Approved Dielectric Red Enamel

Protectant Material

Approved Brands

Spray-On Application

MMM 1602 IVISpray Sealer, Red Electric Grade; order from the PDC

Brush-On Application

Glyptal 1201EW Low VOC, Red; order at www.glyptal.com or 1-800-GLP-1201

Table 2, Approved Dielectric Red Enamel

Repairing Broken Wire

IMPORTANT: The following procedure is the only approved method of repairing broken wires on Freightliner vehicles. This procedure (solder splicing) is done
using solder repair kit ESY ES66 404 and is for 14- or
16-gauge wire. Do not repair wire that is 12 gauge or
larger, replace it instead. The kit contains:
connector ESY 2B14 (PAC PG000638)
sleeve ESY RTS110 0182 (PAC PG000637)
tube 48-02461-038
1. Strip the ends of the wire to be repaired. Make
sure the stripped ends are 3/8- to 1/2-inch (10- to
13-mm) long.
2. If repairing an exterior wire, slip a 3-inch (75-mm)
long piece of heat shrink over one end of the wire.
See Fig. 1.

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54.01

Wiring

Wiring Repair and Replacement

1
A

11/04/94

f540392a

A. 3/8 to 1/2 Inch (10 to 13 mm)

1. Wire End
2. Crimp Splice

3. Solder Sleeve
4. Heat Shrink
Fig. 1, Exterior Wire Repair

3. Slip a solder sleeve from kit ESY ES66 404 over

one end of the wire. See Fig. 1.
4. Using a suitable crimp tool and a crimp splice from
the kit, crimp the ends of the wire as follows:
4.1

Insert a stripped wire end into the crimp

splice until it touches the wire stop in the
middle of the crimp splice.

4.2

Center the crimping tool between the wire

stop and the end of the crimp splice, then
crimp the wire. See Fig. 2.

4.3

Repeat the two substeps above for the

other wire end.

5. Check the crimp, making sure the crimping tool

impression is on both ends of the crimp splice.

Business Class M2 Workshop Manual, Supplement 10, September 2006

6. Slide the solder sleeve over the crimp splice so

the solder ring is over the center of the crimp


splice. See Fig. 3. Then apply 250 F (121 C) heat
until the solder flows into the splice crimp and the
plastic sleeve has shrunk completely against the
wire.
7. Slide the heat shrink over the splice, then apply


250 F (121 C) heat to it until completely shrunk
against the wire insulation. Some of the sealant
material should be bubbling out from the ends of
the heat shrink.

Terminating A Wire End

1. Terminate a cut wire end by installing a 2-inch (50mm) long piece of 1/4-inch (6-mm) diameter or
smaller dual-wall heat shrink at the end of the wire
to prevent water intrusion.

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54.01

Wiring

Wiring Repair and Replacement

A
2

f540395a

11/04/94

A.
1.
2.
3.

Center crimping tool here.

Wire Stop
Wire
Crimp Splice (shown crimped)
Fig. 2, Centering the Crimping Tool

2
4

3
Solder
Crimp Splice (shown crimped)
Wire
Solder Sleeve

11/04/94

1.
2.
3.
4.

f540394a

Fig. 3, Wire Ready for Soldering

2. Slide the heat shrink over the wire end, leaving

about 1/4 inch (6 mm) hanging off the end of the
wire to allow the heat shrink to seal completely to
prevent water intrusion.


3. Apply 250 F (121 C) heat to it until it has completely shrunk against the wire insulation. Some
of the sealant material should bubble out from the
ends of the heat shrink.
4. Clamp the end with pliers as needed to seal the
end of the heat shrink.

100/4

Business Class M2 Workshop Manual, Supplement 10, September 2006

54.01

Wiring

Specifications

Specifications
Standard Wiring Color Coding
Color

Abbr

Typical Usage

Black

BK

Ground, General

Black-White

BK-W

Ground, Clean or Isolated

Blue DK

DKBL

Backup/Wiper/Trailer Auxiliary

Blue LT

LTBL

HVAC/Circulation Fans/1922+

Blue LT-White

LTBL-W Water, Oil Gauge, and Indicator (engine and transmission)

Brown

BR

Marker, Tail, and Panel Lamps

Gray

GY

Electronic Engine (or TXL Insulation)

Green DK

DKG

Turn Signal, Right-side/Drivers Display/Data Record/1587+/

1939

Green
DK-White

DKG-W Starting Aids/Fuel Heaters/Material Control/Winch/Tailgate

Green LT

LTG

Headlamp/Roadlamp/DRL

Green LT-White LTG-W

Axle Controls and Indicators/Suspension/Fifth Wheel

Orange

ABS/EBS/1587

Pink

PK

Start Control/Ignition/Charging/Volt and Ammeter/1922

Pink-White

PK-W

Fuel Control and Indicators/Shutdown/Speed Limiter

Purple

PRP

Engine Fan/PTO/Auto Lube and Oil

Purple-White

PRP-W

Utility/Spot/Ad/Interior/Emergency Lighting

Red

Power Distribution, Constant

Red-White

R-W

Brake/Pneumatic/Hydraulic/Retarder/Stop

Tan

mph, rpm Signals/Horn/Flasher/Pyro/Turbo

Tan-White

T-W

Audio/Video/Security/Window/Computer/Seat/Mirror/Cab-Tilt

White

Transmission (or SXL insulation)

Yellow

Turn Signal, left/1939+ (or GXL insulation)

Yellow-White

Y-W

Air Bag and SPACE

Table 1, Standard Wiring Color Coding

Circuit Numbers and Descriptions

Circuit
Number

Circuit Description

Circuit Numbers and Descriptions

Circuit
Number

Circuit Description

Battery cable, ground

16

Alternator, main power cables, ammeter

Battery cable, 6v positive

18

Air pressure warning/indicator

Battery cable, 6v negative

19

Voltage, meter/alarm

Battery cable, 12v positive

20

Headlamp, left

14

Cab power, main

21

Headlamp, right

15

Starter, engine

22

Headlamp, low beam, left/right

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54.01

Wiring

Specifications

Circuit Numbers and Descriptions

Circuit
Number

Circuit Description

Circuit Numbers and Descriptions

Circuit
Number

Circuit Description

23

Tail lamps

78

Spot lamp

24

Horn, electric

80

Mirror heat, switch and controls

25

Horn, air, electronically controlled

81

Ignition switch control devices

26

Horn, electric, supply

82

Starter mag switch, power supply

27

Roadlamp/foglamp

83

Alternator ground

28

Roadlamp/foglamp

84

Starting aid, glow plug heater

29

Panel/instrument lamps

85

Starting aid, glow plug heater

30

Transmission oil temperature

87

Axle lock

31

Transmission oil temperature, auxiliary

88

Lubrication system, automatic

34

Oil pressure, engine

90

Sander, road

35

Oil temperature, engine

91

Heater, diesel-fired auxiliary

36

Stop lamp

94

Air dryer, heated

37

Turn signal flasher supply

95

Speaker, radio

38

Turn signal

96

Oil level warning

39

Stop/turn combination lamp

97

Air conditioner

40

Fan, windshield/sleeper

98

Heater A/C motor, blower

41

Dome lamp, interior

99

Fuel solenoid, engine run

42

Axle oil temperature, forward

102

Parking lamps

43

Axle oil temperature, rear

103

Parking lamps, right

44

Axle oil temperature, center auxiliary

108

Door activated lamps, courtesy

45

Receptacle, trailer

109

Door control dome lamp, right

46

Marker/parking lamps

113

Baggage compartment lamps

47

Fuel level

117

Speed sensor "+", vehicle, mph/km/h

48

Fuel control and level, natural gas

118

Speed sensor "", vehicle, mph/km/h

52

Ignition switch and controls

119

Coolant temperature, engine

55

Data recorder, speed and tach graph

120

Back up/reverse lamp

57

Outlet, 12v power receptacle/cigar lighter

121

Brake, engine/retarder/compression

58

Heater, auxiliary

122

Back up/reverse alarm

60

Turn signal, left cab

123

Alternator, voltage regulator/rectifier

61

Turn signal, right cab

125

Park brake indicator/warning

71

Ignition switch and controls

131

Alternator NO CHANGE indicator/warning

73

Utility lamp, back of cab

132

Alternator charging system monitor

74

Starter mag switch/solenoid

137

Alternator NO CHANGE indicator/warning

75

Starter mag switch, ground, thermal protection

138

Starter lockout, alternator, ADLO

76

Mirror heat

139

Starter lockout, alternator, ADLO

77

Mirror heat, right mirror supply

140

Oil pressure electronic gauge, engine

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54.01

Wiring

Specifications

Circuit Numbers and Descriptions

Circuit
Number

Circuit Description

149

Fan manual controls, engine

150

Engine protection, shutdown/warning

154

Auxiliary air pressure

155

Axle lift controls

157

Mirror remote power controls

162

Tach sensor "+", engine, rpm

163

Tach sensor "", engine, rpm

166

Starting aid, engine, ether

168

Hour meter, engine

170

Fifth wheel slide lock indicator

171

Brakesaver, CAT

172

Clock

173

Coolant level, engine coolant

178

Idle timer, delayed shutdown, cool down

182

Fuel pressure

183

Air cleaner restriction indicator/warning

191

Starting aid, glow plug, heater

193

Cab tilt pump

196

Fuel/water separator heater

197

Transmission lockup sensor

198

Axle, two-speed shift control

200

PTO controls

203

Exhaust brake

206

Heater A/C with oil pressure controls

208

Axle control, triaxle, steer lock

209

Axle, two-speed shift control

210

Power distribution module (PDM), outside cab

211

Security system, Rockwell

Circuit Numbers and Descriptions

Circuit
Number

Circuit Description

223

Transmission controls, auto shift (axle shift, see

209)

224

Transmission controls (axle shift, see 209)

225

Air pressure gauge, primary

226

Air pressure gauge, secondary

227

Air pressure gauge, application

228

Oil pressure electronic gauge, engine

232

Transmission controls, power harness

234

Fan controls, engine

236

Transmission neutral indicator

240

Fuel/water separator indicator/warning

241

Data recorder, Sangamo tacho graph

242

Seat controls

244

Speed limiter, vehicle, Hewitt

246

Fuel pump, electric

250

Cruise control, Bendix (BW)

253

Cab tilt indicator

254

Emergency lamp, beacon, roof-mounted

255

Advertising lamp

256

Optional power wire

261

Axle lock, controlled differential

262

Retarder, transmission (Allison)

266

PTO controls, transfer case

271

Oil pressure electronic gauge, engine

274

Transmission oil temperature

276

Oil fill system, leveler, Webb (WEI), engine

278

Wiper control, right

279

Wiper control, left

281

Oil filter change indicator/warning, engine

285

Suspension electronic/air controls

286

Fuel/water separator indicator/warning, Racor

(RAI)

212

Refrigerator, power, (no outlet)

214

Generator, auxiliary

215

Heater, diesel-fired auxiliary, Webasto

218

Pyrometer, gauge

292

Fuel tachometer, Flowscan (FOS), Argo (ARG)

219

Turbo pressure gauge

295

Radio, AM/FM/CB

221

Suspension dump controls

299

Air temperature, outside cab

222

Headlamp dimmer controls

300

Radio line level signals

302

CB Radio

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Wiring

Specifications

Circuit Numbers and Descriptions

Circuit
Number

Circuit Description

Circuit Numbers and Descriptions

Circuit
Number

Circuit Description

303

Air pressure, low

363

Window power

304

Back up/reverse lamp

364

Window power, up

305

Ignition switch, accessory

365

Window power, down

306

Ignition switch, run position

368

Coolant temperature gauge, Kysor VIP

309

Park brake indicator/warning

372

Receptacle #2, trailer 7-way, ISO 3731

310

Axle lock

373

Fuel solenoid, engine run

311

Ignition accessory option block

376

Antilock brake system (ABS) controls

312

Radio

377

Antilock brake system (ABS) sensors

313

Turn signal flasher supply

378

Antilock brake system (ABS) valves

314

Turn signal switch supply

379

Daylight running lights (DRL)

315

Wiper

380

Daylight running lights (DRL)

316

Wiper motor low speed

381

Daylight running lights (DRL)

317

Wiper motor park

382

Daylight running lights (DRL), left headlamp

318

Wiper motor high speed

383

Daylight running lights (DRL), right headlamp

319

Wiper motor park

384

Daylight running lights (DRL), program

320

Wiper washer

385

Daylight running lights (DRL), controls

324

Lightbar high coolant temperature

386

Daylight running lights (DRL), left headlamp

325

Lightbar, engine oil pressure

387

Daylight running lights (DRL), right headlamp

326

Lightbar turn signal flasher control

388

Hydraulic brake power and controls

331

Datalink power, diagnostics, SAE J1708

389

Hydraulic brake relay

332

Datalink return, negative

390

Hydraulic brake lamp

333

Air dryer, heated

391

Hydraulic brake relay

334

Door-activated dome lamp

392

Hydraulic brake motor

337

Roadlamp switch

393

Hydraulic brake flow/relay

338

Heater A/C electronic controls

394

Hydraulic brake, park brake lamp

339

Lightbar/cluster power

395

Hydraulic brake fluid sensor

342

Ammeter gauge

396

Hydraulic brake buzzer/alarm

343

Starting aid, glow plug switch, heater

397

Hydraulic brake cab door signal

344

Starting aid, glow plug pressure switch, heater

398

Hydraulic brake motor sense

345

Starting aid, glow plug solenoid, heater

399

Optional wire, cab/chassis, customer furnished

346

Speaker, radio, ground

400

Optional wire, cab/chassis, customer furnished

347

Shutter, engine fan

402

Engine start/stop system, Temp-A-Start (TAS)

349

Shutter, engine fan

404

Data recorder, ARI trip

350

Lightbar, turn signal flasher timing

405

Data recorder

351

Speed limiter, vehicle, lightbar

406

Emergency lamp, alternating flashing

359

Headlamp ON signal, lightbar/cluster

407

Emergency lamp, cross-fire lights

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54.01

Wiring

Specifications

Circuit Numbers and Descriptions

Circuit
Number

Circuit Description

Circuit Numbers and Descriptions

Circuit
Number

Circuit Description

408

Emergency vehicle accessory and warning

lights

446

Tire inflation, Central Tire Inflation System

(CTIS)

409

Emergency lamp, bin lights

447

Battery cutoff protection system, Hewitt (HEW)

410

Emergency siren

448

Tailgate controls, material

411

Emergency fire truck miscellaneous lighting

449

Fueling data recording and transmitter

412

Data recorder, Isspro (ISP)

450

Mirror dimming controls (MSI)

414

Tracking system, vehicle, Sony Geostrat RGSS

453

Body builder/customer furnished wiring

416

Refrigerator/television power, (no outlet)

454

417

Phone power, mobile

Air bag and seat pretensioner activation for

crash system (SPACE)

418

Tool box lamp, left

455

Instrument left/right side selection control

419

Tool box lamp, right

457

Dash controls, datalink, (BPU)

459

Steering pump controls

460

Transmission, automatic, Aisin Seiki, cab

controls

461

Transmission, automatic, Aisin Seiki, chassis/

transmission controls

420

Military 24v lighting, blackout

421

Military 24v lighting and devices, blackout

422

Military auxiliary 24v heater

423

Military, winch controls

424

Headlamp wiper/washer

462

Headlamp, left auxiliary, snow plow

425

Battery cutoff switch controls and bypass

463

Headlamp, right auxiliary, snow plow

426

Air inside/outside indicator

464

Transmission SmartShift control

427

Tracking system, vehicle, satellite

465

Headlamp flashing control

428

Battery isolator protection system

466

Lane departure indicator/tracking system

429

Pyrometer alarm/warning

467

Coolant flow, engine

430

Wiper heater

468

Obstacle detection system (ODS), VORAD

431

Starting aid, engine preheater, grid/flame

469

Level control power, body/chassis

432

Seat controls

470

Datalink transmit

433

Data recorder, Data Hub (DDE)

471

Datalink receive

434

Suspension controls, ECAS

472

Engine control module and controls

435

Seat belt indicator/warning

473

Multifunction turn signal switch

436

Camera, rear and side view

474

Smart switch, resistance identified

437

Instrumentation control unit (ICU), dash display

475

Engine idler controls

439

Engine control module and controls

477

Hazard lights for US Postal Service

440

Engine control module and controls

479

CB antenna

441

Engine control module, alternative fuel vehicles

480

Switched auxiliary air pressure for body builder/

customer

442

Data recorder, Data Logger Unit (DLU)

481

443

Door lock

Address strapping for chassis/expansion

multiplex module

444

Obstacle detection system (ODS), VORAD

482

Emergency firetruck pump controls

Body controls, dump lock

483

Engine control module and controls

445

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54.01

Wiring

Specifications

Circuit Numbers and Descriptions

Circuit
Number

Circuit Description

487

Electronic engine emissions detection and

monitoring

500

Hydraulic brake ECU, brake signal

502

Oil level warning, engine low

503

Starting aid, engine preheater, flame start

505

Gauge sender, optional

516

Starting aid, engine preheater, flame start

1587

Datalink, diagnostics, SAE J1587

1922

Datalink, controls, SAE J1922

1939

Datalink, controls, SAE J1939

BAT

Main battery power

GND

Ground, miscellaneous cab/chassis

OPT

Optional wiring, spare or customer furnished

B###

Bendix antilock brake system (ABS)

C###

Caterpillar electronic engine

D###

Detroit Diesel electronic engine (DDE)

E###

Allison electronic transmission

N###

Cummins electronic engine

S###

Spicer AutoMate transmission

T###

Twin Disc automatic transmission

W###

Eaton Ceemat/AutoShift transmission

X###

WABCO anitlock brake system (ABS); see 376,

377 and 378

Table 2, Circuit Numbers and Descriptions

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Business Class M2 Workshop Manual, Supplement 10, September 2006